Redbook: Guidelines for Hazard Evaluation Procedures Redbook Overview

Transcription

1 Redbook: Gidelines for Hazard Evalation Procedres Redbook Overview Kelsey Forde CIH CHMM Owner, Principal EHS Professional Parvati Conslting LLC (505)

2 Historical Perspective Pblished By Center for Chemical Process Safety (CCPS) Established in 1985 by American Institte of Chemical Engineers Develop & Disseminate Technical Information Spporting HE Prevention of Major Chemical Accidents Gidelines 1st Pblished in 1985 Crrent (3rd Ed) Gidelines Encompass Lessons Learned from Indstry Accidents US Chemical Safety & Hazard Investigation Board (CSB) Recommendations for Hazard Evalations Process Safety Management Implementation Laws & Reglations International Standards Experience Gained Since 1985 with Performing Hazard Evalations 2

3 Redbook Sm of Parts Part I Hazard Evalation Procedres Gidelines Describes Methods Used to Identify & Assess Hazards Management Overview Nine Chapters Follow Flow of Performing Hazards Analysis Part II Worked Examples and Appendices Companion to the Gidelines Examples for Novice Analyst Examples for Training 3

4 Redbook Do s & Don ts Gidelines Do Provide Insights To Be Considered When Making Risk Management Decisions & Designing Risk Management Programs Expectations for High Qality Hazard Evalations Aid for Initial Training of Hazards Analysts Reference Material for Experienced Hazard Analysts Gidelines Don t Provide A Complete Hazards Analysis Program Specific Advice On How to Establish HA Program Replace Hazards Evalation Experience of Qalified Analysts 4

5 Redbook Improvements 3 rd Edition In Depth Discssion Inherent Safety Reviews & HE Concepts HE Methods Divided Non-Scenario Based Scenario Based Scenario Risk Estimation To Determine Adeqacy of Controls 5

6 Redbook Improvements 3 rd Edition New Sections HE with Layer of Protection Analysis (LOPA) Evalating Procedre Based Operations Evalating Programmable Systems Facility Siting Isses Hman Factors Added to Hman Reliability Analysis HE Reviews for Management of Change Integration of HE with Reliability & Secrity Additional Checklists & Forms In Chapters & Appendix A 6

7 Redbook Otline & Flow RB - Page 9 7

8 Gidelines Overview Smmarizes the Use of HE Techniqes as Integral Part of a Process Safety Management Program Describes How HE Techniqes Used Throghot Life of Process/Facility Realistic Expectations for Managers What HE Provides Limitations of Common Techniqes 8

9 Gidelines Overview HE Organized Effort to Identify & Analyze the Significance of Hazards/Hazardos Sitations with a Process or Activity HE Used to Pinpoint Weaknesses in Design & Operation of Facilities that Cold Lead to Impact from Hazards HE Information to Aid in Decisions for Improving Safety & Managing Risk of Operations HE Focs on Process Safety Isses With Workers & Pblic HE Complement Traditional Health & Safety Worker Assessments 9

10 Gidelines Overview HE Performed Throghot Life of Process Lifecycle Approach Early Stages of R&D Detailed Design & Constrction Periodically Throghot Operation Decommissioning & Dismantlement Efficiently Reveal Deficiencies In Design & Operation 10

11 Gidelines Overview Non-Scenario Based Preliminary Hazards Analysis Safety Review Relative Ranking Checklist Analysis Scenario Based What-If Analysis What-If/Checklist Analysis Hazard & Operability (HazOp) Stdies Failre Modes & Effects Analysis (FMEA) Falt Tree Analysis (FTA) Event Tree Analysis (ETA) Case Conseqence Analysis (CCA) & Bow Tie Analysis Other Techniqes 11

12 Gidelines Overview Redbook Part I Gidance on Process Safety Management Program Redbook Part II Aid in Training & Experience Redbook Part I & Part II Analyst Understand Basics of HE Performing HE of Simple Processes Using Simple HE Methods Redbook Part I & Part II Together with Experience Analyst Scope, Organize, Lead, & Docment HE Facilitator Role for Analyst 12

13 Gidelines Overview Benefits of HE Program Fewer Incidents Over Life of Process Redced Conseqences of Incidents Improved Emergency Response (Understanding of Hazards) Improved Training & Understanding of Process More Efficient & Prodctive Operations Improved Reglatory & Commnity Relations 13

14 Gidelines Overview HE Program Reqires Significant Investment Completion of HE Reqires Time (Hors to Months) Docmentation, Training, & Staff/Material Resorces Need Strategy to Use Properly Trained/Skilled Analysts Select Appropriate HE Techniqe Techniqe Commensrate with Problem Available Information Conseqence/Risk Ensre Effort Not Wasted by Over-Stdying a Problem with a More Detailed Approach than Necessary 14

15 Gidelines Overview HE Limitations Never 100% Certainty for Identification of All Hazards, Events, Cases, and Effects Reslts & Benefits Cannot Be Directly Verified Based on Existing Knowledge or Process/Operation Qality Reflected in Drawing Accracy, Procedre Accracy, & Process Knowledge Dependent on Sbjective Jdgment, Assmptions, & Experience of Analysts Cannot Garantee Incidents Will Not Occr Limitation Provides Jstification Periodic HE Throghot Lifecycle Jstification for Management of Change (MOC) 15

16 Gidelines Overview HE Provides Valable Inpt for Risk Redction For Pillars Establish Risk Based Process Safety Understanding Hazards and Risks Committing to Process Safety 1. Developing and Sstaining a Cltre that Embraces Process Safety 2. Identifying, Understanding, & Complying With Codes, Standards, Reglations, and Laws 3. Establishing and Continally Enhancing Organizational Competence 4. Soliciting Inpt from Stakeholders Employees, Contractors, & Neighbors Manage Risks Learn from Experience 16

17 Chapter 1 Introdction to Gidelines Describes How HE Techniqes Fit Into PSM Program Relates Use of HE Techniqes to Risk Management Introdces Terminology Used for Evalating Process Hazards In Context of a Typical Incident Seqence of Events Introdces Role of Safegards in Preventing & Protecting Against Upsets & Mitigating the Impacts of Loss Events How HE Techniqes can be Used Throghot Lifetime Otlines Important Theoretical & Practical Limitations of HE Techniqes Smmarizes Expectations from Use of HE Techniqes 17

18 Chapter 2 Preparation of Hazard Evalations Describes Infrastrctre Needed to Spport HE Program Gives Examples of Scope Statements for HE Otlines the Skills & Information for HE Addresses Schedle & Logistical Considerations for HE 18

19 Chapter 3 Hazard Identification Methods Importance of Identifying Hazards Contemporary Approaches for HI Use of Experience in Analyzing Material Properties & Process Conditions Several Strctred Approaches for HE (with Examples) Describes Types of Reslts Expected from HI 19

20 Chapter 4 & 5 Hazard Evalation Techniqes Difference Between Scenario & Non-Scenario Based HE Non-Scenario Based Experienced Based on Facility/Team Experience Efficient at Broad Brsh for Hazards Review Applied Early in Design/Operation for Safety Improvement Efforts Scenario Based Predictive & Analytical Systematically Determine What Can Go Wrong Systematically Determine Safegards Applied Throghot Process Lifecycle Divided Into 2 Grops Wide Range of Hazards Specific Use in Special Sitations 20

21 Chapter 4 Non-Scenario Hazard Evalations Non-Scenario Based HE Techniqes Prpose, Description, Types of Reslts, Resorce Reqirements, & Analysis Procedre For Each Techniqe 4 Non-Scenario Based HE Techniqes Preliminary Hazards Analysis (PHA/PreHA) Safety Review Relative Ranking Checklist Analysis Illstrates Each Method with a Brief Example 21

22 Chapter 5 Scenario Hazard Evalations Scenario Based HE Techniqes Prpose, Description, Types of Reslts, Resorce Reqirements, & Analysis Procedre For Each Techniqe 8 Scenario Based HE Techniqes What-If Analysis What-If/Checklist Analysis Hazard & Operability (HazOp) Stdies Failre Modes & Effects Analysis (FMEA) Falt Tree Analysis (FTA) Event Tree Analysis (ETA) Case Conseqence Analysis (CCA) Hman Reliability Analysis (HRA) Illstrates Each Method with a Brief Example 22

23 Chapter 6 Selection of HE Techniqes Factors Inflence Selection of Appropriate HE Techniqe Qestion Based Flowchart to Choose HE Techniqe Selection Criteria 23

24 Selection of HE Techniqes 24

25 Chapter 7 Risk Based Determination Gidelines for More Detailed Evalation of Scenario Risks Basic Concepts of Estimating Loss Event Impacts, Initiating Freqency, and Safegard Effectiveness Examples Comparing Risks for Determining Adeqacy of Safegards Use of Layer of Protection Analysis (LOPA) 25

26 Chapter 8 Analysis Follow-Up Importance of Prioritizing Reslts List of Identified Hazards Description of Significance of Events/Hazards Recommendations for Redcing/Eliminating Isses Ideally Rank Soltions Verss Rank Problems Rank Via Immediate Actions, Planned Actions, & Frther Evalations Importance of Docmenting Reslts Consolidate & Preserve Reslts for Ftre Use Provide Evidence Performed Per Sond Engineering Principles Spport Other PSM Activities Gidelines for Commnicating Reslts Strategies for Management of Change 26

27 Chapter 9 Extensions/Special Applications Combining Tools HazOp with LOPA What-If with LOPA Special Topics Evalating Hazards for: Procedre Based Operations Programmable Control Systems Reactive Chemical Systems Hman Factors Consideration of Hman Factors Completing Hman Reliability Analysis Facility Siting, Layot, & Facility-Based Personal Protection 27

28 Part II Worked Examples Example Description of Facility & Process Example HI Example HE Techniqes R&D: What-If Analysis Conceptal Design: PreHA Pilot Plant: HAZOP Detailed Engineering: FTA/ETA Constrction/Start-p: Checklist Analysis & Safety Review Rotine Operation: Safety Review for Management of Change Rotine Operation: HAZOP Stdy for Cyclic Review Plant Expansion: Relative Ranking & HAZOP for Batch Process Incident Investigation: FMEA & HRA Decommissioning: What-If/Checklist Analysis 28

29 Gidelines Appendices Example Checklists & Forms for HE Legend of Symbols & Abbreviations for Drawings Commercially Available Software Aids for Performing Hazard Evalations Chemical Compatibility Chart Process Safety Enhancement Resorces 29

30 Follow Up with Parvati Kelsey L. Forde, CIH, CHHM (505) Facility/Worker Safety Redbook Training Redbook Overview Redbook HE Techniqes What-If/Checklist Failre Modes & Effects Analysis Hazard & Operability Analysis Timothy S. Stirrp, IH, REM (505) Layer of Protection Analysis (LOPA) Risk Analysis Inherent Safety Reviews Perform Process Hazards Analysis Facilitate Hazard Evalations Peer Review PHA (HI + HE) STAMP/STPA Traditional ES&H/IH Services 30